ESAB Unveils Cutmaster X Series: Plasma Cutting Redefined with Revolutionary Torch and Consumable Design!

Thermal Dynamics, a brand under ESAB, has introduced the Cutmaster X 90 and Cutmaster X 110 plasma cutters, marking what the company calls one of the most significant advancements in plasma cutting technology in decades. With a redesigned arc starting mechanism, new consumables system, and a flexible 1TorchFLEX torch design, these new systems aim to deliver faster performance, longer life, and improved ease of use for professionals across manufacturing, fabrication, and repair industries.

At the heart of the new series is a completely re-engineered arc starting mechanism. Unlike conventional plasma systems that rely on moving parts to establish an arc, the Cutmaster X models employ a solid-state design that initiates the arc within mere thousandths of a second once airflow begins. This innovation eliminates mechanical wear and delivers a faster, smoother start every time. According to Kris Scherm, Global Product Manager at ESAB, “The Cutmaster X arc starting mechanism represents the biggest innovation in plasma cutting in decades. Starting the arc in a few thousandths of a second improves cutting performance, and users rank fast arc starts and steady cutting power among their most requested features.”

Another key advancement lies in the all-new consumables design. Traditionally, operators have to replace entire sets of consumables even if only one component wears out. ESAB’s new system allows users to replace only the worn parts — reducing downtime and cutting operating costs. The redesigned cutting tip, cup, and cap work together to extend consumable life, ensuring consistent cut quality and long-term savings.

The newly developed 1TorchFLEX adds further versatility. Its articulating head can flex from 30 to 90 degrees and lock securely in position, giving users improved access to complex joints during cutting and gouging operations. The inclusion of dedicated consumables for both cutting and gouging makes the system even more flexible for varied applications.

In terms of performance, the Cutmaster X 90 delivers 90 amps at over 50% duty cycle, capable of piercing and cutting material up to 7/8 inch thick, with a severance capacity of 1.75 inches. The Cutmaster X 110 operates at 110 amps with similar duty cycle ratings and can pierce up to 1 inch while severing material up to 2 inches thick. Despite their industrial-grade performance, both units are surprisingly compact and portable, weighing approximately 60 pounds.

The systems are designed for global compatibility and convenience. They automatically connect to single-phase or three-phase power between 200 and 600 volts without manual linking. The new industrial housing enhances durability in rugged work environments, while a large digital display and intuitive interface simplify operation and reduce training time.

Additional smart features include automatic detection of inlet and outlet air pressure, a post-cut air purge system to extend consumable life, and a 14-pin CPC connection that enables automation or integration with ESAB’s MechPak for semi-automated applications.

With these upgrades, the Cutmaster X 90 and X 110 redefine what users can expect from a plasma cutter — delivering faster starts, higher precision, reduced maintenance, and greater flexibility. For fabricators, manufacturers, and maintenance professionals seeking high performance and low operating costs, ESAB’s new Cutmaster X series sets a new benchmark in plasma cutting technology.